Ceiling panel of bonded fibrous glass with an integrated hanger element

ABSTRACT

A ceiling panel having a body of fibrous glass held to shape by a resinous binder and preferably made rigid at least in part by compression while the binder is set, and a hanger element such as a hook, spring clip or a tongue for lodgement upon or engagement with a receiving surface or apertured holder such as a spring clip as provided in the structure of a steel beam, the hanger element being integrated with the body of fibrous glass through a resinous material such as the resinous binder or one compatible therewith and the resinous material being in sufficient quantity to extend into and make rigid the adjacent portion of the body of fibrous glass.

United States Patent 1191 1111 3,817,014

Jones 1 June 18, 1974 CEILING PANEL 0F BONDED FIBROUS 3,378,972 4/1968 Stanley 52/309 GLASS WITH AN INTEGRATED HANGER 3,417,530 12/1968 Long 52/484 X ELEMENT 3,418,777 12/1968 Gillis 52/529 X 3,492,771 2/1970 Jones et a1. 52/144 X [75 Inventor: Isaac Palmer Jones, Granville, Ohio FOREIGN PATENTS OR APPLICATIONS Assigneel Owens-Corning Fiberglas 190,094 0/1963 Sweden 52/494 Corporation, Toledo, Ohio [22] Filed: Apt 5 1968 Primary Examiner-Henry C. Sutherland Assistant Examiner-Henry E. Raduazo PP 0; 719,208 1 Attorney, Agent, or FirmStaelin & Overman 52 us. Cl 52/478, 52/494, 52/601 ABSTRACT [51] Int. Cl E041) 1/82 A ceiling panel having a body of fibrous glass held to 1 Fleld of Search shape by a resinous binder and preferably made rigid /5 161/43 at least in part by compression while the binder is set, and a hanger element such as a hook, spring clip or a References Cited tongue for lodgement upon or engagement with a re UNITED STATES PATENTS ceiving surface or apertured holder such as a spring 1,803,390 5/1931 Howard 52/144 Clip as Provided in the Structure of a Steel beam the 1,945,564 2/1934 Piazza 52/494 hanger element being integrated with the y 2,213,296 9/1940 Zinser 161/43 x brous glass through a resinous material such as the 2,257,499 9/1941 Hasenburger et al 52/497 X resinous binder or one compatible therewith and the 2,266,599 12/1941 Hasenburger et a1 52/478 resinous material being in suff cient quantity to extend Schaub et a1. X and make adjacent of 3,269,076 8/1966 Strand 161/44 x of fibrous glass 3,312,030 4/1967 Gillespie 52/497 3,336,705 8/1967 Vecchiarelli et a1 52/497 X 8 Claims, 8 Drawing Figures f a z'g'g". i 1 6 I j 9 5 j Z; a'j zjgfl w [5 if 14 {a J PKTENTEDJum m4 1x18171014 saw 1 or 2 INVENTOE [544a JONAS 44 TTORNEYS PATENTEBJum-m 3317.014

INVENTOR.

[SA/1C P Jo/vas CEILING PANEL OF BONDED FIBROUS GLASS WITH AN INTEGRATED HANGER ELEMENT This invention relates generally to a panel for use in contiguous, planar series to function as a ceiling or as a sheathing over existing ceiling structures.

More specifically this invention relates to a panel composed of fibrous glass suitable for heat or sound insulation and relates further to such a panel of fibrous glass which is shaped by compression and maintained in its compressed condition by the curing of a binding agent with which it is impregnated.

Glass fibers for the products of this invention are more commonly and preferably of a diameter between fifteen and thirty, hundred thousandths of an inch but may have diameters inthe range between three and one hundred, hundred thousandths. Such fine fibers are produced by well established processes utilizing high pressure steam jets, or high velocity, superheated gases to attenuate streams'of molten glass. As these fibers, in various lengths, usually not surpassing several inches, drop away from the forming station they are impregnated with a phenol formaldehyde binding material discharged from adjacently positioned spray devices.

Other effective binder material may have compositions of urea formaldehyde, epoxies, polyesters or melamines. Such thermosetting compositionsare considered most suitable although thermoplastic binders while less satisfactory, could be utilized. Instead of short fibers, but less desirable from the standpoint of economy continuous filaments or strands of continuous filaments may be employed.

When laid directly upon plaster or other flat ceiling structures panels are conventionally secured in place through adhesive material daubed at spaced points on their rear surfaces.

The borders of the panels, when the latter are destined for adhesive attachment, may be beveled or chamfered for decorative effect but otherwise have no special edging for alignment or supporting purposes. The backing wall or ceiling is relied upon to provide an even surface as the panels are spaced therefrom only by the amount of the adhesive substance and there is accordingly slight leeway within which the planar position of each panel may be varied in respect to the ceiling surface.

In those cases where the panels are mounted at some distance below the ceiling level they are mechanically supported upon or from steel beams of various cross sections, hung from ceiling joists. One common practice is to slot or kerf the edges of the panels for receipt of the lateral projections of such hanger members and for the insertion of splines to maintain the panels in coplanar relation. Alternately the panels may be laid upon the horizontal flanges of the steel beams. This leaves the beams exposed which may not be decoratively acceptable. The panels may be provided with tongue and groove, rabbet-joint or other matching edges for cooperative alignment and support.

The panels may also be secured in place by staples or nails when applied over a suitably penetratable surface of wood or composition wallboard or where furring strips of wood have been attached to the surface for this purpose.

It may be noted that these various methods of mounting panels where the hanger beams are not exposed either require special curfing of the edges of the panels or the time consuming application of adhesive or of insertion of a plurality of individual fasteners such as staples or nails.

Accordingly, a primary object of this invention is to provide a ceiling panel that may be installed without the need of adhesives or a plurality of separate fastening members.

A further object of this invention is to provide a panel of a design which facilitates quick and efficient installation thereof.

More specifically it is the object of this invention to present a panel having hanger elements solidly integrated therewith, and in combination with beams with structure engageable by said elements.

These and other objects and benefits of the invention are attained mainly through the incorporation of a hanger means by resinous bonding to the rear face of the panels as set forth the following description and the accompanying drawings in which:

FIG. 1 is a perspective view showing one manner of securing the panels of this invention to ceiling joists;

FIG. 2 is a perspective view of a panel embodying one form of the invention;

FIG. 3 shows a friction clip hanger element which may be incorporated in the panel;

FIG. 4 is a view of a spring clip which may be substituted for the friction clip of FIG. 3;

FIG. 5 shows an alternate form of panel and integrated hanger element;

FIG. 6 is a sectional view thereof taken on the line 6-6 of FIG. 5;

FIG. 7 is a perspective view of a supporting beam incorporating a spring clip structure for supporting the panel of FIGS. 5 and 6; and

FIG. 8 is a vertical section of an installation of panels of the design depicted in FIGS. 5 and 6.

Referring to the drawings in more detail, the panel 10 of FIGS. 1 and 2 has integrated hanger elements 12, one of which is shown separately in FIG. 3.

V The panel 10 is generally rigid with an average density which may be in the range of ten to eighteen pounds per cubic foot. The density ofthe bonded fibrous glass portions adjacent the locations of the hanger elements 12 is preferably greater than the average density and may extend as high as forty or more pounds per cubic foot and have a resinous binder content between fifteen and twenty five per cent by weight.

The elements 12 are preferably integrated with the body of the panel 10 when the latter is compressed in thickness or molded under pressure and the settingis effected of the resinous binder, which may have a composition for instance of phenol formaldehyde resin.

During the compression of the binder impregnated fibrous glass body blank the hanger elements are pressed against the body blank forcing part of the binder in the body blank into concentrated contact with the elements. If there is insufficient binder to thus respond to the pressure upon the elements an extra amount of the binder or of a settable resinous adhesive compatible with the binder is first applied to the surface of the body blank at the points where the elements are to be placed or such extra resinous material is first applied to the faces of the hanger elements to be adjoined to the body blank.

With each of these procedures a very strong, and possibly solid resinous, linking layer is established in the fibrous structure of the panel beneath the elements which are thus integrated in the compression and setting operation.

In FIG. 1 is shown one form of suspension structure upon which the panels may be mounted. It includes steel rails or beams 14 secured with nails to ceiling joists 16. In this illustration ends of the joists are shown abutting against wall 18. A panel supporting moulding strip is fastened to the wall.

Both the friction clip 12 of FIG. 3 and the spring clip 22 of FIG. 4 are adapted for hanging the panels 10 upon the suspension structure of FIG. 1.

In the procedure of installing the ceiling of panels 10, a panel is first placed with an edge over the moulding while sliding the clips 12 or 22 over the lower horizontal leg of the adjacent S-section steel beam 14.

The upper lip 24 of the next panel 10 to be installed is placed over the depressed ledge edge 26 of the first positioned panel while the hanger elements 12 of the second panel engage the lower horizontal leg of the next S-section beam 14. The ceiling is thus covered by the continued installation of panels lap-jointed. as shown. There is no need of a high number of staples, nails or adhesive daubs and a smooth planar ceiling surface is provided with no members of the suspension system observable.

Another mode of practicing the invention is depicted in FIGS. 5, 6, 7 and 8. The panel 28 of FIG. 5 embodies an alternate form in which the hanger elements comprise angle steel elements 30 secured to the edges of the panel in the same manner as are the clips 12 and 22 to panel 10.

The narrow indented borders of panel 28 have been compressed to a greater extent than the central portion of the panel. This establishes a density in the edge areas more adaptable to the purposes of the invention and permits the central portion to be left at a lower density than might be feasible for panel 10 in which the same thickness prevails throughout the whole panel expanse. Lower densities with greater thickness generally enhance the sound attenuating and thermal insulating properties of the panel.

In FIG. 7 is shown a steel beam 33 adapted to receive and hold the vertical flanges of hanger elements 30. A pair of spring legs 34 of the beam are angled upwardly toward each other to a point of at least approximate contact.

A parallel series of the beams 33 are secured to the crosswise arrangement of joists 35 as indicated in FIG. 8. Nails, screws or other types of penetrating fasteners may be used to hold the beams in place.

A wall moulding (not shown) would likely be employed to support one edge of the panel 28 adjacent to the wall. The opposite edge of the first panel would be supported by thrusting the panel upwardly with the vertical leg of the hanger element 30 forcefully introduced between the pair of spring legs 34.

The vertical leg of the hanger element 30 on the near edge of the next panel 28 installed is forced between the spring legs 34 of the same beam while the vertical leg of the element on the far side of the panel is introduced between the legs of the next beam. With the balance of the panels similarly positioned an easy and accurate installation of the panels is accomplished.

It may be noted that hanger elements 30 with mitered ends may be lengthened to meet at the corners of the panels to form a continuous metallic frame for the panel which would not only strengthen the panel but could provide a closed insulating air space behind the panel on installation thereof.

Other forms of hanger elements than those disclosed herein are of course adaptable for incorporation with panels of this invention. They should be of quite rigid material at least in the portion thereof attached to the panel, and that portion should preferably be substantially flat and of fair sized area. Metal hanger elements would likely serve most satisfactorily although a plastic composition could certainly be utilized.

Steel beams are considered most suitable, although beams of aluminum or other metals may be substituted there for.

While the invention has been herein applied to panels generally rigid across their full planar dimensions, the main body of the panels may be flexible as long as there is sufficient coherence to maintain the shape of the panel and to prevent tearing away from the densified areas where the hanger elements are integrated.

The essence of the invention lies principally in the integration of the hanger elements with the fibrous glass ceiling panels and the substantially solid resinous union therebetween at rigid portions of the panel.

The field of the invention extends also to the combination of such panels with ceiling beams, preferably of steel composition, having structure particularly designed to engage and hold the hanger elements.

As indicated, various changes and substitutions may be made in respect to the specific embodiments herein presented for purposes of explanation and disclosure. These would generally be of a nature coming within the spirit of the invention and the scope of the appended claims.

I claim:

1. A generally flat ceiling panel having a body of fibrous glass held to compressed shape by a resinous agent and hanger means integrated with said body by resinous material, there being a substantially solid layer of said material disposed largely within the boundaries of the body of fibrous glass but also extending to the upper generally planar surface thereof beneath the hanger means and constituting the integrating link between the hanger means and said body, said body being rigid in portions adjacent said solid layer of said material, and being compressed to a higher density and lesser thickness in said portions than in other portions generally of said body.

2. A ceiling panel according to claim 1 in which the resinous agent and resinous material are of the same composition.

3. A ceiling panel according to claim 1 in which the hanger means includes a plurality of clips positioned in spaced relation along one border of the panel.

4. A ceiling panel according to claim 3 in which the clips have generally parallel arms one of which lies flat against the body of the fibrous glass and constitutes the portion of the clip through which the clip is integrated with the body of fibrous glass.

5. A ceiling panel according to claim 1 in which the hanger means includes a member extending along one border of the panel and having a flange portion extending perpendicularly from the planar dimension of the panel.

6. A generally flat ceiling panel having a generally low density compressed body of fibrous glass held to shape by a resinous binder with a planar surface on its 7. A generally flat ceiling panel according to claim 6 in which the resinous adhesive is: a concentrated portion of the resinous binder.

8. A generally flat ceiling panel according to claim 6 in which deep penetration of the resinous adhesive into the adjacent portion of the body is secured through the greater compression of the said part of the body. 

1. A generally flat ceiling panel having a body of fibrous glass held to compressed shape by a resinous agent and hanger means integrated with said body by resinous material, there being a substantially solid layer of said material disposed largely within the boundaries of the body of fibrous glass but also extending to the upper generally planar surface thereof beneath the hanger means and constituting the integrating link between the hanger means and said body, said body being rigid in portions adjacent said solid layer of said material, and being compressed to a higher density and lesser thickness in said portions than in other portions generally of said body.
 2. A ceiling panel according to claim 1 in which the resinous agent and resinous material are of the same composition.
 3. A ceiling panel according to claim 1 in which the hanger means includes a plurality of clips positioned in spaced relation along one border of the panel.
 4. A ceiling panel according to claim 3 in which the clips have generally parallel arms one of which lies flat against the body of the fibrous glass and constitutes the portion of the clip through which the clip is integrated with the body of fibrous glass.
 5. A ceiling panel according to claim 1 in which the hanger means includes a member extending along one border of the panel and having a flange portion extending perpendicularly from the planar dimension of the panel.
 6. A generally flat ceiling panel having a generally low density compressed body of fibrous glass held to shape by a resinous binder with a planar surface on its upper face, a rigid hanger element with a flat base portion attached to the planar surface through resinous adhesive between the flat base portion and the planar surface, said resinous adhesive extending into the adjacent portion of the ceiling panel and increasing the rigidity and density thereof, the part of the body beneath said planar surface being compressed to a greater density and lesser thickness than the general remainder of the body.
 7. A generally flat ceiling panel according to claim 6 in which the resinous adhesive is a concentrated portion of the resinous binder.
 8. A generally flat ceiling panel according to claim 6 in which deep penetration of the resinous adhesive into the adjacent portion of the body is secured through the greater compression of the said part of the body. 